Maintenance

Post build general maintenance & servicing information to keep the car on the road. i.e. the must do fixes due to wear and tear, breakages or consumables. Larger jobs, or those worth a picture, may have an explicit blog entry.



    Maintenance log:

    • 2013 - 176 Miles
    • 2014 @ 3.5k Miles - start of season service
      • Change oil (3.5k)
      • Change coolant/antifreeze (lost on overheat)
    • 2015 @ 5.5k Miles - start of season service
      • Lubricate Prop-shaft UJs
      • Change Timing belt - engine age
      • Check plug gaps
      • Change oil (2.5k)
      • Change oil Filter
    • 2015 @ 9k Miles
      • Replace flexible fuel lines - originals cracking externally
      • Change fuel filter
    • 2016 @ 11.8k Miles - start of season service
      • Clean air intake filter
      • Change coolant/antifreeze (during radiator replacement)
      • Differential oil topped up
    • 2016 @ 12.8k Miles
      • Change oil (7.3k)
      • Change oil filter
      • Engine Map to adaptive mode
    • 2016 @ 15k Miles
      • Silencer rattle repair - FOC - Kitspares
      • Clocks delaminating decals repair - FOC - Caerbont
    • 2017 March @ 16.3k Miles
      • Differential oil topped up
    • 2017 April @ 18.5k Miles
      • Clutch cable adjusted for more throw - crashing on 1st and reverse
      • Front indicators replaced - nearside broken lens
      • Steering column lower bush replaced - play upper steering column
      • Seat nuts and bolts replaced - worn down wear and tear
      • Handbrake adjusted
    • 2017 May @ 18.8k Miles
      • Rear wheel bearings replaced - play in offside
      • Spark plugs changed - routine
      • All Tyres replaced - wear and tear, esp on rears
      • Bonnet chrome (plastic) trim replaced - wear and tear
    • 2017 June @ 19.5k Miles
      • Clutch cable replaced - pedal end flange broken
      • Change Oil (6.7k) and Oil filter
      • IACV Air filter changed
    • 2017 Aug @ 20.1k Miles
      • Lubricate Prop-shaft UJs
      • Diff oil top up
    • 2018 June @ 24k Miles
      • Brake fluid change
      • Front shocks replaced
    • 2019 April @ 25.5k Miles
      • Change Oil (6k) and Oil filter
      • Clean out oil pump sump pickup grille
      • Replace sump washers with dowty washers
      • Lubricate Prop-shaft UJs
      • Check and top up diff oil
    • 2020 January @ 28.5k Miles
      • Replace water temp sensor & radiator thermostat 88ºC
      • Replace number plate lamp
    • 2020 May @ 28.5k Miles
      • Replace head gasket
      • 16PSI coolant cap
    • 2020 October @ 28.5k Miles
      • Top up diff oil
      • Adjust handbrake cable
    • 2021 May @ 28,619
      • Change Oil (3.1k)
      • Top up diff oil
    • 2021 Dec @ 28,619
      • Replace Battery (not holding a charge anymore)
    • 2025 June @ 28,619
      • Replace seats 
    • 2026 Jan @ 28,619
    • Clean stat/stat housing, flush and refill engne coolant @ 30% antifreeze

      Parts reference:

      Log of parts used on the Zero, OEM, upgrades, future reference.
      Yellow = not certain/not necessarily tried myself yet

      Interior

      • Seat mounting holes ~12" left/right, fore/aft

      Lights

      • Headlamps: H4 - Philips X-treme vision 
      • Tail lights: P21/5
      • Tail indicators: PY21W
      • Front indicators: 23W BA9S

      Brakes

      • Front pads: Mintex MDB1175M1144, (Ferrodo DS2500 FCP206H)
      • Front discs: BM002 240x24mm, Offset 58, Bore 64, PCD 108 (e.g. RallyDesign)
      • Rear pads: Mintex MDB12871144, (Ferrodo DS2500 FCP408H)
      • Rear discs: 257x22mm PCD 108 (Sierra XR4 Rear disc?)
      • Fluid: DOT4 ~0.5L

      Engine

      • Engine build: 17/08/2004, Zetec E Black top (Phase 3)
      • Diff Oil: SAE 75W90 EP GL5 Gear Oil
      • Engine Oil: 5w30 Semi-synthetic, ~5 litres
      • Gearbox Oil: 75W90 Semi-synthetic GL4
      • Engine coolant: ~4.5 litres
      • Raceline sump plug washer: 21mm ID, 27mm OD, 1mm thick or 3/4" & 1/2" BSP dowty
      • Oil Filter: Fujitoyo FO-9217 or Trupart FO9217 or LS934 - O/D:80mm, Thread: 3/4x16UNF, H:79mm, Anti drain, PRV: 13-16
      • Fuel Filter: Sytec 8mm/8mm SSF2070 (Larger than OEM filter)
      • Spark Plugs: NGK Platinum NGKPTR5A-10
      • Spark Plug Gap: 1.0mm
      • Timing belt/Kit: SKF VKMA 04214
      • Rocker cover gasket: search for Ford Focus, Mondeo 2.0 Gasket kit: RC8328
      • Alternator/Water Aux pump Belt: DAYCO 5PK 1100 - 5 rib, 1100mm 
      • Alternator: Nippon Denso A073 5v 40A: 103 400354, 02 512-206(Kubuta A2198 60A?, LEA100-88LW 60A?)
      • Radiator (not GBS/OEM): VW Polo 1983-1990 380x323mm core (e.g. Ebay)
      • Radiator cap: OBP PC003 (16psi) was OBP PC004 (20psi)
      • Lambda Sensor Wideband: Bosch LSU 4.9 -  17025 0-258-017-025 -4UG
      • Starter Motor: LRS707 (unconfirmed)
      • LP Fuel Pump: Facet 40105k 3-4.5psi 1/8"npt 30USg/hr ?60106 backup? FUE0023?
      • HP Fuel Pump: Sytec HI P3017.1 OTP017 12mm / 8mm push on (spare) (Bosch 044?) FUE0011
      • Injectors: Bosch 0-280-155-820 18.25Lb/Hr  191.8cc/min 138g 43.5PSI 3Bar
              14.5ohms, 169g/min @ 380kPa, 150.2g/min 215ml/min @ 300kPa
      • IACV: Normal operation : 7-13 Ohms
      • Clutch Cable (OEM routed inside engine mount) 92cm/73cm
      • Thermostat 54mm diameter, 22.5mm bottom, 17.8mm top 88ºC: (QT100K 82º, QT101K 74º QT102K 88º QT107K 92º)  QT102K fitted
      • Radiator backup thermostat switch: M22x1.5 98-93ºC  FAE 37400
      • Coolant sensor (ECU) E450
      • Battery type '063' 40Ah 340CCA (175mm x175mm x207mm)
      • Clutch plate: 'com934 3n' clutch kit 23 tooth spline, 240mm (may be MT75 specific - check)

      Suspension and Wheels

      • Weight with driver: 760kg, distribution front: 340kg, rear: 420kg
      • Tyre pressure: 20psi (was 18, trying a little higher to even tyre wear)
      • Steering Rack: Escort Mk2 - 260mm mounting centres, 1095mm total length, M14 threads, 2.4 quick rack
      • Track rod ends: Sierra:  Ball joint:M10x1mm fine
      • Wheels: 7Jx15" 4x108 ET15
      • Tyres: 195/50 R15 82V: Current: Hankook Ventus V12 evo2(K120), Yokohama Parada (18.8k 4years - spare)
      • Wheel nuts: M12x1.5 (Spare/boot rods M12x1.25)
      • Front wishbone bottom ball joint: Astra Mk3 (Delphi Lockheed part TC397)
      • Front wishbone top ball joint: Ford Transit track rod end FTR4700
      • Rear wheel bearings: Sierra 2WD - OD: 60mm ID: 35mm width 19mm BRT990
      • Suspension arm bushes: Powerflex PF99-113P, PF99-113 (TBC) Kitspares SUS0033
      • Shocks/Springs: Protech
      • Front shocks: 1.9" ID spring seats, 14" open length, bushes M12 - T:25mm, B:20mm
      • Rear shocks: 1.9" ID spring seats, (Ford)12"
      • Front springs: 9" 350lbs 1.9" ID
      • Rear springs: 8" 275lbs 1.9" ID, (originals were 8" x 250)
      • Geometry: 
        • Shocks front: Protech +2 clicks (Clockwise = harder)
        • Shocks rear: Gaz +9 clicks (was 5, 10, 7)
        • Chassis to ground: Rear 130mm, Front 120mm (Factory uses 120,110)
        • Front: 0º04' toe-in each side, -1.3º camber
        • Rear: not adjustable (Needs Shims) - target 0º29' toe in, -1.3º camber


      Loom Connectors and Components

      Useful for adding new circuits on spare pins.

      • Narrowband Lambda 4 pin Socket: Deutsch DTM
      • 6.3mm blade connectors: Durite (Interparts)
        • 2 way T: 0-011-13, 0-011-03
        • 4 way: 0-011-15, 0-011-05
        • 11 way: 0-011-18, 0-011-08
        • Female terminal: 0-011-023 <1mm² -24 >1mm²
        • Male terminal: 0-011-021 <1mm² -22 >1mm²

      Mouser part numbers

      *Thank you to Marlin Press in California, a fellow Zero builder, for finding and sharing the Dashboard and Engine loom connector part numbers!

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